Triumph TROPHY 1949 Manuals

Manuals and User Guides for Triumph TROPHY 1949. We have 1 Triumph TROPHY 1949 manual available for free PDF download: Workshop Instruction Manual

Triumph TROPHY 1949 Workshop Instruction Manual (213 pages)

Brand: Triumph | Category: Motorcycle | Size: 13.51 MB

Introduction
5
Service Arrangements
6
Correspondence
6
Orders
6
Technical Advice
6
Proprietary Fittings
7
Speed Twin Technical Data
8
Thunderbird Technical Data
10
Ignition
10
Carburetor
10
Clutch
11
Sprockets
11
Chain
11
Trophy Technical Data
12
Tiger Technical Data
14
Control Layout
18
Left Hand
18
Right Hand
18
Controls - Instruments
19
Speedometer
19
Lighting Switch
19
Horn Button
19
Ignition Switch
20
Ammeter
20
Steering Damper
20
Oil Pressure Indicator
20
Adjustment of Controls and Riding Position
21
Kickstarter
21
Footrests
21
Gearchange Lever
21
Taking over the Machine
22
Air Cable
22
Magneto Cable
22
Clutch Cable
22
Petrol Tap Positions
23
Starting the Engine
24
Running-In
25
Engine Lubrication System
27
Lubrication Maintenance
27
Engine
27
Oil Tank
29
Oil Pump
29
Oil Release Valve and Indicator
30
Oil Pipes
30
Crankcase Scavenge Pipe
30
Valve Rockers, Rocker Spindles and Push Rods
30
Gearbox
31
Primary Chaincase
31
Cycle Parts
31
Chains
31
Changing the Oil
32
Oil Tank Filter
32
Crankcase Filter
32
Routine Maintenance after Running-In Period
33
The Engine
35
Crankcase
35
Flywheel and Crankshaft
35
Cylinder Block
35
Crankshaft Assembly
36
Index
37
Tappet Adjustment
38
Adjusting the Tappets
38
Decarbonising
39
Rocker Adjuster Pin
39
Dismantling
40
Saddle
40
Exhaust System
40
Torque Strays
40
Re-Assembly
41
Cylinder Head
41
Inlet Rocker Box
41
Exhaust Rocker Box
41
Removing the Engine from the Frame
42
Petrol Tank
42
Testing
42
Twinseat
43
Dynamo
43
Control Cables
43
Dismantling the Engine
44
Oil Pressure Release Valve
44
Engine in Vice
44
Crankshaft and Camshaft Nuts
45
Distributor Gear
45
Magneto Gear
45
Camwheels
45
Removing the Camwheel
46
Crankshaft Pinion
46
Cylinder Head and Rocker Boxes
46
Removing the Crankshaft Pinion
47
Crankshaft Pinion Removal Tool
47
Dismantling, Preparation and Assembly of the Engine Units
48
Rocker Boxes
48
Valves and Springs
48
Removing Carbon from Cylinder Head
49
Replacing the Valve Guides
49
Re-Cutting the Valve Seats
49
Assembling the Cylinder Head
49
Assembling the Tappet Block
50
Recommended Rebore Oversizes
51
Tappets
51
Tappet Blocks
51
Pistons
51
Taper Faced Piston Ring Position
52
Chrome Taper Faced Ring Position
52
Valve Push Rods and Cover Tubes
53
Crankcase Unit
53
Main Bearing
53
Scavenge Pipe
53
Refitting the Main Bearings
54
Timing Cover
54
Timing Gears
54
Inspection and Identification
55
Checking Connecting Rod Bolt Stretch
56
Assembling the Engine
57
Crankcase, Driving Side
57
Camshaft
57
Sump Filter
57
Valve Timing
60
Magneto
60
Timing Diagrams
60
Installing the Engine
63
Positioning the Contact Breaker
70
Final Operation
70
Sparking Plug Leads
70
Replacing the Distributor and Driving Pinion
70
Timing
71
Setting the Contact Breaker Points
71
Piston Positioning
71
Correct Positioning of the Distributor
72
Check the Timing
72
Faulty Gear Selection
73
Quadrant Plunger Sticking
73
Camplate Plunger Sticking
73
Component Parts
74
Removing the Gearbox from the Frame
76
Dismantling the Gearbox
78
Gearbox Outler Cover
78
Gearbox Inner Cover
78
Gear Cluster
78
Gearbox Outer Cover
79
Kickstart Assembly
79
Clutch Operating Lever
79
Gearchange Mechanism
79
Gear Operating Quadrant
80
Bearing
80
Speedometer Drive
80
Gearbox Casing
80
High Gear
81
Replacing the Chain Sprocket and Nut
81
Gearbox Casing in Vice
81
Assembling the Gearbox
82
Mainshaft Gears
82
Layshaft Gears
82
Installing the Gearbox
83
Rear Chain
83
Cables
83
Primary Chaincase Inner Cover
83
Pivot Bolt
84
Rear Engine Plates
84
Oil Tank and Air Cleaner Unit
84
Clutch and Shock Absorber Unit
85
Replacement of the Cork Inserts
85
Overhaulting the Clutch Dismantling
85
Removal of Clutch Nuts
87
Clutch Plates
88
Engine Mainshaft Nut
88
Brake Pedal
88
Removing the Shock Absorber Rubbers
89
Replacing New Shock Absorber Rubbers
89
Outer Retaining Plate
89
Clutch to Mainshaft Nut
90
Clutch Housing
91
Clutch Hub
91
Clutch Locking Tool
91
Drive Shaft Adaptor
91
Preparation and Inspection
92
Clutch Springs
92
Cork Plates
92
Steel Plates
92
Engine Sprocket
93
Outer Pressure Plate
93
Clutch Cable Adjustment
93
Chaincase Outer Cover
93
Tachometer Drive
94
Tension
94
Gearbox Clamp Bolt
94
Adjuster
94
Rear Chain Adjustment
95
Gearbox in Position
95
Adjusters
95
Securing Wheels
95
Primary Chain Adjustment
96
Gearbox Pivot Bolt
96
Securing Gearbox
96
Wheel Nut
97
Wheel Securing
97
Chain Maintenance
97
Cleaning and Greasing the Rear Chain
97
Alterations and Repairs
98
Maintenance
100
Draining
100
Re-Filling
100
Adjusting the Steering Head Races
100
Removing the Fork from the Frame
101
Testing the Adjustment of the Steering Head Races
101
Handlebar
101
Stanchion Cap Nuts
101
Telescopic Fork
102
Dismantling the Fork
104
Dismantling the Pressure Tube Assembly
104
Top Lug
104
Middle Lug Pinch Bolts
104
Dismantling, Preparation and Assembly of Units
105
Bottom Cover Tubes
105
Springs
105
Pressure Tube Assembly
105
Aligning the Front Fork
106
Alignment
107
Assembling and Installing the Fork
107
Drain Plugs
107
Steering Races
107
Assembling the Fork
108
Nacelle Top Unit
108
Headlamp Assembly
108
Mudguard
108
Changing the Main Springs
109
Cap Nut
109
Fork Crown Pinch Bolt
109
Headlamp
109
Wheels
110
Adjusting the Brakes
110
Front Brake
110
Rear Brake
110
Front Wheel
111
Removing the Front Wheel from the Forks
111
Dismantling the Front Wheel
111
Spindle Nut
111
To Dismantle the Front Brake Anchor Plate
113
Inspection and Replacement of Worn Parts
113
Washing
113
Brake Drum
113
To Assemble the Front Brake Anchor Plate
115
Brake Cam
115
Brake Shoes
115
Assembling the Front Wheel
116
Fitting the Front Wheel to the Front Fork
116
Spindle
116
Anchor Plate
116
Correct Alignment of Front Wheel in Forks
117
Rear Wheel
118
Rigid Frame
118
Removing the Rear Wheel from the Frame
118
Dismantling the Rear Wheel
120
Dismantling the Rear Brake Anchor Plate
120
Roller Races
120
Return Springs
120
Assembling the Rear Brake Anchor Plate
121
Assembling the Rear Wheel
121
Brake Operating Spindle and Cam
121
Bearing Backing Ring
121
Fitting the Rear Wheel to the Frame
122
Anchor Plate Assembly
122
Chain Adjuster Thrust Collar and Spindle Nut
122
Positioning the Wheel
122
Final Bearing Adjustment
123
Brake
123
Road Test
123
Brake Torque Stay
123
Removal of Brake Drum and Sprocket
130
Dismantling the Brake and Drum Sprocket Assembly
130
Dismantling the Anchor Plate Assembly
130
Brake Drum Bearing
131
Sleeves
131
Felt Washer
131
Assembling the Q.D. Rear Wheel
132
Dust Covers
132
Locking Nuts
132
Spring Wheel
133
Removal of the Wheel from the Frame
133
Rear Spring Wheel
135
Brake Anchor Plate
136
Slipper Roller
136
End Plate
136
Aluminium Shims
136
Plunger Guide Box Assembly
137
Brake Drum and Sprocket
137
End Plate Bearing
137
Dismantling the Plunger Guide Box Assembly
138
Plunger Guide Box
138
Slipper Pads
138
Roller and Slipper Pads
138
Brake Cam Spindle
139
Casings
139
Re-Fitting the Wheel to the Frame
140
Large Cast Iron Ring
140
Brake Anchor Plate Assembly
140
Dust Excluder Assembly
140
Tyres
141
Tyre Pressure
141
Dunlop Recommended Tyre Pressures
141
Examination
141
Fitting the Tyre
142
Removing the First Bead
142
Inner Tube
142
Removing the Second Bead
142
First Bead
143
Second Bead
143
Valve
143
Security Bolt
143
Frame
144
Swinging Fork
144
Girling Suspension Damper Units
144
Girling Hydraulic Suspension Unit
145
To Increase the Static Spring Rate
146
Changing the Springs
146
Maximum Movement
146
Twistgrip Control
147
Cable Thimble
147
Rotor Sleeve
147
Head
147
Grub Screw
149
Rotor Sleeve Stop
149
Petrol Tap Adjustment
150
Push-Pull Type
150
Taper Type
150
Fitting a Sidecar
150
Cleaning Motorcycle
151
Amal Carburetor
152
Operation of Carburetor Parts
152
Throttle Stop Screw
152
Pilot Air Screw
152
Swinging Arm Frame
154
Air Filter
154
Defects in Operation
159
Check for Air Leaks
159
Sticking of Piston
159
Bent Needle or Incorrectly Centred Jet
160
Eccentricity
160
Flooding from Float Chamber or Mouth of Jet
161
Leakage from Bottom of Jet
161
Hints and Tips
161
The Float Chamber
161
Plastic Cap
162
Piston Spring
162
Lucas Electrical Equipment
163
Lighting and Magneto Ignition
163
Ammeter Readings
163
Inspection of Brushgear and Commutator
163
Wiring Diagram
164
Adjustment of Contact Breaker Setting
166
Cleaning Contacts
166
Removal of Contacts for Cleaning
166
High Tension Pick-Up
166
Circuit Details
167
Emergency Starting
167
Primary Chaincase Cover Removed to Show Rotor and Stator
168
Rating
170
The Alternator
170
Ignition Coil
171
Contact Breaker Unit
171
Contact Breaker Setting
172
High Tension
172
Engine will Not Start
173
No Spark at Plugs
173
Distributor, Coil or Condenser Faulty
173
Lamps
174
Engine Runs with Swtich on
174
Headlamps Fitted to the TRS Models
174
Replacing the Headlamp Bulb
174
Setting the Headlamp Beam
175
Trs
175
Headlamp and Top Nacelle Unit
176
Parking Lamp
176
Rear Lamp
176
Retaining Ring
176
Battery
177
Horn
177
Lighting and Ignition Switch
177
Checking the Condition of the Battery
178
Taking Hydrometer Readings
178
Detachable Cable Connectors
179
Battery Earth
179
Electric Horns
179
Sparking Plugs
180
Ash White
181
Dull Black
181
Light Brown
181
Toolkit
182
Supplementary
184
Cylinder Head Bolts
185
Fault Finding and Maintenance
187
Special Insrtuctions
187
Crankcase Assembly
188
To Assemble the 3T Crankshaft
189
Exploded View of Top Portion
192
Lubrication of Parts
194
Lubrication Chart
200
Recommended Lubricants
202
Overseas
203
Fault Finding
204
Engine Stops
205
Engine Misfires
205
Loss of Power
206
Engine Overheats
206
Engine Revolutions Per Minute
207
Gear Ratios
207
Illustrated Index
208
Index of Contents
211

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Triumph TROPHY 1949 Workshop Instruction Manual (213 pages)

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